Apparatus and methods for manufacturing cigarette tubes

ABSTRACT

Pre-formed cigarette tubes are provided in an automated fashion. Cigarettes containing a filler material are manufactured according to known methods and transferred to an apparatus for removing the filler material. The filler material within each resulting cigarette is removed therefrom. Optionally, the filler material may be recycled to the beginning of the process. The resulting pre-formed cigarette tubes are collected. At a later time, the hollow regions of those pre-formed tubes can be filled with tobacco cut filler in order to provide finished cigarettes.

FIELD OF THE INVENTION

The present invention relates to smoking articles, and in particular, to cigarettes. More specifically, the present invention relates to equipment and methods for manufacturing, in an automated fashion, filtered cigarette tubes that are later used for cigarette manufacture.

BACKGROUND OF THE INVENTION

Smoking articles, such as cigarettes, have a substantially cylindrical rod-shaped structure and include a charge, roll, or column of smokable material, such as shredded tobacco, surrounded by a paper wrapper, to form a “cigarette rod,” “smokable rod” or a “tobacco rod.” Normally, a cigarette has a cylindrical filter element axially aligned in an end-to-end relationship with the tobacco rod. Typically, a filter element comprises plasticized cellulose acetate tow circumscribed by a paper material known as “plug wrap.” Certain cigarettes incorporate filter elements comprising, for example, activated charcoal particles. Typically, the filter element is attached to one end of the tobacco rod using a circumscribing wrapping material known as “tipping paper.” A ventilated or air diluted smoking article can be provided with an optional air dilution means, such as a series of perforations, each of which extend through the tipping material and plug wrap.

A variety of hand operated devices for manufacturing individual cigarettes have been proposed. In particular, various manners and methods for filling paper cigarette tubes with tobacco have been proposed. See, for example, U.S. Pat. No. 2,633,133 to Higgins; U.S. Pat. No. 3,124,141 to Seitter; U.S. Pat. No. 3,202,156 to Kappeler et al.; U.S. Pat. No. 3,892,245 to Asbill, Jr.; U.S. Pat. No. 4,167,948 to Moscovitch; U.S. Pat. No. 4,572,216 to Josuttis et al. and U.S. Pat. No. 5,072,740 to Gatschmann et al. See, also, U.S. Pat. No. 3,491,768 to Paynter and U.S. Pat. No. 3,693,313 to Sexstone which set forth manners and methods for manufacturing individual cigarettes by filling a tube or “spill” with a tobacco charge and a filter plug.

One type of cigarette making machine for the manufacture of one cigarette at a time using loose tobacco and a filtered cigarette tube has been marketed as “Bugler” filter cigarette making machine by Brown & Williamson Tobacco Corporation. Another type of automated machine for filling pre-formed cigarette tubes with loose tobacco filler has been available commercially as “Cig-a-mat” from Jenkins & Ott, Inc. A device representative of such a machine is described in U.S. Pat. No. 3,645,272 to Jenkins et al. Yet another type of automated device for filling pre-formed cigarette tubes with tobacco filler is an electrically operated cigarette making machine that has been available commercially as Easy Roller from C. P. Rolling ApS of Denmark. See, also, the types of devices set forth in U.S. patent application Ser. No. 11/375,700, filed Mar. 14, 2006, to Thomas et al., which is incorporated herein by reference.

A cigarette machine for filling empty pre-formed cigarette tubes with tobacco filler has been produced commercially by The Central Tobacco Mfg. Co. Ltd. and marketed as “Premier Supermatic.” Other types of cigarette machines for filing cigarette tubes with tobacco have been marketed as “Escort” and “Pressta Deluxe” by CTC Canada Inc. See, for example, the representative types of machines set forth in U.S. Pat. No. 3,127,900 to Kastner and U.S. Pt. No. 4,771,793 to Kastner. Other types of cigarette machines for filing cigarette tubes with tobacco are available as “Premier Twin,” “Filterite Twin” and “Rayo Twin” through American Thrust Tobacco, LLC.

U.S. Pat. No. 3,822,710 to Bramhill proposes manufacturing individual cigarettes by inserting a cartridge of compressed tobacco into an empty filter tip cigarette tube. Other manners and methods for manufacturing individual cigarettes are set forth in U.S. Pat. No. 4,887,617 to Ruppert et al.; U.S. Pat. No. 5,018,536 to Liebich; U.S. Pat. No. 5,105,830 to Brackmann et al.; U.S. Pat. No. 5,133,366 to Liebich; U.S. Pat. No. 5,141,000 to Ruppert et al.; U.S. Pat. No. 5,167,241 to Ruppert al.; U.S. Pat. No. 5,197,495 to Ruppert et al.; U.S. Pat. No. 5,615,692 to Ruppert et al. and U.S. Pat. No. 5,713,377 to Gerding et al.

As can be seen, many cigarette making machines, such as the cigarette making machines described above, require a supply of pre-formed cigarette tubes. Representative pre-formed filtered cigarette tubes have been available commercially as Premier Filter Tip Tubes from C.T.C. Canada Inc.; MacDonald Export “A” Express Kit Medium Regular Size Cigarettes Tubes from RJR-MacDonald Inc.; and Escort King Size Filter Tip Tubes from C.T.C. Canada Inc. Other representative pre-formed tubular wrapper portions have been available under the trade names Excel, Century, Zig-Zag, Bugler, Twister, Rayo, Gizeh, Vera Cruz, Laramie, The “Three Castles” Tobacco, and Zen. Representative pre-formed tubular wrapper portions have been made available through companies such as HBI International, Clinton Tube Company (USA) and American Thrust Tobacco, LLC.

There are a number of manners and methods for manufacturing cigarettes using pre-formed cigarette tubes. Accordingly, it is desirable to provide a method and apparatus for making uniform cigarette tubes in an efficient and cost-effective manner.

SUMMARY OF THE INVENTION

A method of manufacturing a pre-formed cigarette tube is provided. The method includes the steps of manufacturing a cigarette using a cigarette making machine, transferring the cigarette to an apparatus for removing the filler material from the cigarette, and removing the filler material from the cigarette. The method may also include the steps of collecting the filler-material that is removed from the cigarette and transporting the filler material back to the cigarette making machine.

A machine is also provided for manufacturing pre-formed cigarette tubes. The machine includes a cigarette making machine for making cigarettes that include a filler material. The machine also includes an apparatus for removing the filler material from the cigarettes and an apparatus for transporting the cigarettes from the cigarette making machine to the apparatus for removing the filler material. The machine may also include an apparatus for recovering the filler material that is removed from the cigarettes and an apparatus for transporting the recovered filler material to the cigarette making machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a pre-formed filtered cigarette tube that may be made in accordance with the methods and apparatus of the present invention.

FIG. 2 is a flow-chart of one embodiment of a method of manufacturing pre-formed cigarette tubes in accordance with the present invention.

FIG. 3 is a flow-chart of one embodiment of a machine for making pre-formed cigarette tubes in accordance with the present invention.

FIG. 4 is a flow-chart of one method of screening recycled filler material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An example of a preferred cigarette tube that can be manufactured pursuant to the present invention is shown in FIG. 1. Referring to FIG. 1, there is shown a longitudinal cross-section of a pre-formed filtered cigarette tube 21. Such a tube has the general shape of a cigarette, but is virtually devoid of the smokable filler material that makes up a finished cigarette. The cigarette tube 21 includes a hollow generally cylindrical region 1200 defined by cigarette paper wrapping material 1205 into which tobacco cut filler is intended to be inserted. The tubular wrapper 1205 is configured for receiving tobacco cut filler to provide a finished cigarette; that is, for providing a wrapped, smokable tobacco rod. The cigarette tube 21 most preferably also includes a filter element 1210 positioned at one end thereof. The filter element 1210 preferably is attached to the wrapping material 1205 using a circumscribing tipping material 1215. The tipping material most preferably circumscribes the entire length of the filter element, and an adjacent region of the tubular wrapper (e.g., about 3 mm to about 6 mm of the length of the tubular wrapper). The filter element 1210 includes filter material 1220 (e.g., cellulose acetate tow plasticized using triacetin) wrapped in a circumscribing plug wrap material 1225. The tipping material 1215 and plug wrap 1225 may optionally, though preferably, include a line of perforations 1230 (e.g., at least one circumscribing ring of a series of individual perforations), in order that during use of the cigarette that is manufactured using the cigarette tube, mainstream smoke drawn through the cigarette can be air diluted. The perforations 1230 may be provided during or after cigarette manufacture using on-line laser perforation techniques, or the relevant wrapping materials may be pre-perforated.

The dimensions of a representative pre-formed filtered cigarette tube 21, and hence the finished cigarette manufactured therefrom, can vary. Preferred representative cigarettes are rod shaped, and can have circumferences of about 17 mm to about 27 mm, but most preferably about 22.5 mm to about 25 mm; and can have total lengths of about 80 mm to about 100 mm. The length of the filter element can vary. A typical filter element can have a length of about 20 mm to about 40 mm. In one preferred embodiment, the cigarette tube has a diameter of about 7.5 mm, the length of the filter element 1210 is about 27 mm, and the length of the cylindrical region 1200 that forms the tobacco rod is about 56 mm. In another preferred embodiment, the cigarette tube has a diameter of about 7.5 mm, the length of the filter element is about 31 mm, and the length of the tobacco rod is about 66 mm. For a representative preferred pre-formed filtered cigarette tube, tipping paper 1215 can circumscribe the entire filter element and about 4 mm of the length of the paper wrapping material 1205 in the region adjacent to the filter element. Furthermore, for a representative preferred pre-formed filtered cigarette tube, a circumscribing ring of air-dilution perforations is positioned at least about 13 mm to about 15 mm from the extreme mouthend of the filter element.

The wrapping material 1205 that is used to construct the hollow tubular portion of the pre-formed cigarette tube 21 can have a wide range of compositions and properties. The selection of a particular wrapping material will be readily apparent to those skilled in the art of cigarette design and manufacture, and can be a matter of design choice. There is most preferably one layer of wrapping material. Exemplary types of wrapping materials, wrapping material components and ingredients, and treated wrapping materials, are described in U.S. Pat. No. 5,220,930 to Gentry and U.S. Pat. No. 6,868,855 to Shafer et al.; and U.S. Pat. Pub. Nos. 2004/0134631 to Crooks et al.; 2005/0016556 to Ashcraft et al.; 2005/0076929 to Fitzgerald et al. and 2006/0027243 to Matsufuji et al.; and EP 1234514 to Grider et al.; which are incorporated herein by reference. The wrapping materials of the tubular wrapper portions can be treated with additive materials. For example, those materials can be treated with formulations incorporating ethylcellulose, starch, alginate, or the like. Representative manners and methods for treating such wrapping materials are set forth in U.S. Pat. No. 5,878,753 to Peterson et al.; U.S. Pat. No. 5,5,878,754 to Peterson et al. and U.S. Pat. No. 6,779,530 to Kraker; U.S. Pat. Pub. Nos. 2005/0016556 to Ashcraft et al.; 2005/0076929 to Fitzgerald et al.; 2006/0021625 to Nyffeler; and U.S. patent application Ser. No. 11/251,632, filed Oct. 14, 2005 to Oglesby; which are incorporated herein by reference.

A preferred method of making cigarette tubes, particularly pre-formed filtered cigarette tubes of the type set forth hereinbefore, will now be described. In general, pre-formed cigarette tubes are made by manufacturing finished cigarettes and removing the filler therefrom. More particularly, in the preferred embodiment, a continuous cigarette rod is provided, using a conventional type of cigarette making equipment. The continuous cigarette rod, which possesses a filler material circumscribed by wrapping material, is cut at pre-determined intervals in order to provide a plurality of cigarette rods, each of a pre-determined length. The individual cigarette rods are transported to a tipping region, where a filter element segment is attached to one end of each tobacco rod. Optionally, each cigarette can be air diluted (e.g., using laser perforation techniques). Then, the filler material within each resulting filtered cigarette is removed therefrom. The resulting pre-formed tubular wrapping portions are collected. In an alternative embodiment, the filler material that is removed from the each cigarette is collected, and put through a recycling process for use in the further manufacture of future cigarette tubes. A flow-chart of one embodiment of a method of making pre-formed cigarette tubes in accordance with the present invention is provided as FIG. 2. Similarly, a flow-chart of one embodiment of a machine for making pre-formed cigarette tubes in accordance with the present invention is provided as FIG. 3

An automated cigarette tube making system can be used for the manufacture of cigarette tubes for personal use (e.g., for use at home, whereby a consumer fills the tubes with his/her choice of tobacco), for the manufacture of specialty type cigarettes within tobacco products retail establishments (e.g., for the production of individual packages of cigarettes at tobacco shops, such as can be produced using the types of devices set forth in U.S. patent application Ser. No. 11/375,700, filed Mar. 14, 2006, to Thomas et al.), for the manufacture of small lots of cigarettes for quality control or regulatory related activities, or for research and development purposes. That is, the pre-formed cigarette tubes are useful for the manufacture of finished cigarettes using a wide variety of manual and automated cigarette making devices.

The preferred method of manufacturing cigarette tubes will now be described in greater detail. First, numerous individual cigarette rods are manufactured using a cigarette making machine. A conventional automated cigarette rod making machine useful in carrying out the present invention is of the type commercially available from Molins PLC or Hauni-Werke Korber & Co. KG. For example, cigarette rod making machines of the type known as Mk8 (commercially available from Molins PLC) or PROTOS (commercially available from Hauni-Werke Korber & Co. KG) can be employed, and can be suitably modified in accordance with the present invention. A description of a PROTOS cigarette making machine is provided in U.S. Pat. No. 4,474,190 to Brand, at col. 5, line 48 through col. 8, line 3, which is incorporated herein by reference. Types of equipment suitable for the manufacture of cigarettes also are set forth in U.S. Pat. No. 4,781,203 to La Hue; U.S. Pat. No. 4,844,100 to Holznagel; U.S. Pat. No. 5,156,169 to Holmes et al.; U.S. Pat. No. 5,191,906 to Myracle, Jr. et al.; U.S. Pat. No. 6,647,870 to Blau et al.; U.S. Pat. No. 6,848,449 to Kitao et al.; and U.S. Pat. No. 6,904,917 to Kitao et al.; and U.S. Pat. Pub. Nos. 2003/0145866 to Hartman and 2005/1094014 to Read, Jr.; which are incorporated herein by reference. The preferred cigarette making machines manufacture cigarettes at a high speed.

The components and operation of conventional automated cigarette making machines will be readily apparent to those skilled in the art of cigarette making machinery design and operation. For example, descriptions of the components and operation of several types of chimneys, tobacco filler supply equipment, suction conveyor systems and garniture systems are set forth in U.S. Pat. No. 3,288,147 to Molins et al.; U.S. Pat. No. 3,915,176 to Heitmann et al; U.S. Pat. No. 4,291,713 to Frank; U.S. Pat. No. 4,574,816 to Rudszinat; U.S. Pat. No. 4,736,754 to Heitmann et al. U.S. Pat. No. 4,878,506 to Pinck et al.; U.S. Pat. No. 5,060,665 to Heitmann; U.S. Pat. No. 5,012,823 to Keritsis et al. and U.S. Pat. No. 6,360,751 to Fagg et al.; and U.S. Pat. Pub. No. 2003/0136419 to Muller; which are incorporated herein by reference. The automated cigarette making machines of the type set forth herein provide a formed continuous cigarette rod or smokable rod that can be subdivided into formed smokable rods of desired lengths.

The filler material can be any material that can be used in the cigarette making process, and subsequently can be removed from the cigarette to yield an empty cigarette tube. Filler materials employed for manufacture of the continuous cigarette rod typically have forms, and are used in manners, that are traditional for the manufacture of smoking articles, such as cigarettes.

The filler material most preferably includes a tobacco material, and in certain circumstances the filler material is composed entirely of tobacco material. Preferably, the filler material is can be characteristic of the so-called “cut filler” material traditionally employed in the operation of conventional automated cigarette making machines (e.g., shreds or strands of tobacco filler shredded or cut into widths of about 1/20 inch to about 1/60 inch, often about 1/25 inch to about 1/50 inch, frequently about 1/30 inch to about 1/45 inch, and in lengths of about ¼ inch to about 1 inch). Additionally, the filler material can be composed of pieces of tobacco lamina, parts of tobacco stems, pieces of processed tobacco (e.g., reconstituted tobacco, processed tobacco stems, expanded tobacco, or the like), or mixtures or blends thereof. In certain circumstances, tobacco filler materials can be straight grade materials; that is, only one type of tobacco (e.g., flue-cured tobacco or burley tobacco) is used for cigarette rod manufacture. Preferred tobacco filler materials are materials that exhibit good integrity, and have a propensity not to degrade into fines during successive cigarette rod manufacturing operations. Most preferably, the tobacco filler materials do not incorporate, or have not been treated with, additives (e.g., processing aids, flavoring agents, top dressing components, non-aqueous casing components, and the like). In certain circumstances, the tobacco filler materials can be absent of additives, and can be grown under conditions specified by the U.S. Department of Agriculture as being required for the production of crops that might be designated as “organic.” Filler materials are most preferably tobacco materials not possessing additive materials or substantial amounts of additive materials, or materials used for the manufacture of cigarettes (e.g., paper materials) in order that any residual filler material that is not removed from the cigarette tube so formed does not have the propensity to introduce any significant degree of contamination to the finished cigarette that is subsequently manufactured from that cigarette tube.

The filler material can be a material other than tobacco, or the filler material can be a mixture of tobacco material and another filler material. Such other materials preferably have general physical characteristics (e.g., size, shape, weight, density, and the like) that are similar to tobacco cut filler traditionally used for cigarette rod manufacture. For example, in addition to standard cut tobacco, tobacco substitute materials can be employed as some or all of the filler material used for the manufacture of pre-formed tubes. The filler material may comprise shredded tobacco stem, paper, pulp, wood, plastic, plants, and mixtures thereof. The filler material may be woven or nonwoven, particulate, shredded, or granular. Exemplary plastics include polymers such as polyethylene and polystyrene. Preferably, the filler material has a density and consistency that is approximately the same as tobacco filler.

Various tobacco substitute materials have been proposed. Substantial listings of various types of tobacco substitute materials can be found in U.S. Pat. No. 4,079,742 to Rainer et al. and U.S. Pat. No. 4,771,795 to White et al. Certain cigarette-type products that employ non-tobacco materials (e.g., dried vegetable leaves, such as lettuce leaves) as filler that is burned to produce smoke that resembles tobacco smoke have been marketed under the trade names “CUBEBS,” “TRIUMPH,” “JAZZ,” and “BRAVO.” For example, such materials are described in U.S. Pat. No. 4,700,727 to Torigian. Furthermore, tobacco substitute materials having the trade names “CYTREL” and “NSM” were introduced in Europe during the 1970s.

Representative types of proposed synthetic tobacco substitute materials, smokable materials incorporating tobacco and other components, and cigarettes incorporating those materials, are described in British Pat. No. 1,431,045; and U.S. Pat. No. 3,738,374 to Bennett; U.S. Pat. No. 3,844,294 to Webster; U.S. Pat. No. 3,878,850 to Gibson et al.; U.S. Pat. NO. 3,931,824 to Miano et al.; U.S. Pat. No. 3,943,941 to Boyd et al.; U.S. Pat. No. 4,044,777 to Boyd et al.; U.S. Pat. No. 4,233,993 to Miano et al.; U.S. Pat. No. 4,286,604 to Ehretsmann et al.; U.S. Pat. No. 4,326,544 to Hardwick et al.; U.S. Pat. No. 4,920,990 to Lawrence et al.; U.S. Pat. No. 5,046,514 to Bolt; U.S. Pat. No. 5,074,321 to Gentry et al.; U.S. Pat. No. 5,092,353 to Montoya et al.; U.S. Pat. No. 5,778,899 to Saito et al.; U.S. Pat. No. 6,397,852 to McAdam; and U.S. Pat. No. 6,408,856 to McAdam. Furthermore, various types of highly processed smokable materials incorporating tobacco and other ingredients are set forth in U.S. Pat. No. 4,823,817 to Luke; U.S. Pat. No. 4,874,000 to Tamol et al.; U.S. Pat. No. 4,977,908 to Luke; U.S. Pat. No. 5,072,744 to Luke et al.; U.S. Pat. No. 5,829,453 to White et al. and U.S. Pat. No. 6,182,670 to White et al.

Filler material can be provided using techniques familiar in the art of tobacco blend formulation and preparation. Filler material can be provided using blending drums, air transport devices, or other suitable means that provides adequate physical mixing of pieces of filler material. It is highly desirable that the filler material, whether as single strain or blended form, have the form of a consistent mixture in terms of distribution of particle size, density of components and composition of components. The amount of filler material normally used within each formed tobacco rod ranges from about 0.6 g to about 1 g. The tobacco filler normally is employed so as to fill each tobacco rod at a packing density of about 100 mg/cm3 to about 300 mg/cm3, and often about 150 mg/cm3 to about 275 mg/cm3.

It is desirable that the moisture content of the filler material, and in particular tobacco filler material, be sufficiently high so that the filler does not undergo an undesirable degree of degradation during handling and processing associated with the process steps of the present invention. It also is desirable that the moisture content of the filler material not be so high that the filler material clumps during handling and processing. Preferably, cigarette rods are manufactured using tobacco filler material having a moisture content of about 12 weight percent to about 13 weight percent.

The individual formed tobacco rods most preferably have filter elements attached thereto, typically using known types of components, techniques and equipment. For example, the cigarette rod making machine can be suitably coupled to filter tipping machine, such as a machine available as a MAX, MAX S or MAX 80 Hauni-Werke Korber & Co. KG. See, also, for example, U.S. Pat. No. 3,308,600 to Erdmann et al. and U.S. Pat. No. 4,280,187 to Reuland et al; which are incorporated herein by reference. Various manners and methods for attaching filter elements to cigarette rods are set forth in U.S. Pat. No. 2,809,640 to Oldenkamp; U.S. Pat. No. 4,077,415 to Preston et al.; U.S. Pat. No. 4,236,535 to Schmidt et al.; U.S. Pat. No. 4,237,907 to Pawelko et al.; U.S. Pat. No. 4,340,074 to Tudor; U.S. Pat. No. 4,361,156 to Hall; U.S. Pat. No. 4,431,010 to Seragnoli; U.S. Pat. No. 4,583,558 to Luke; U.S. Pat. No. 4,841,993 to Hinz et al; and U.S. Pat. No. 5,228,462 to Osmalov et al.; and U.S. Patent Application Pub. Nos. 2003/0172942 to Schlisio and 2003/0205235 to Draghetti; which are incorporated herein by reference. For example, there are provided representative manners or methods for supplying a series of two-up filtered cigarette rods, each having two smokable rods and filter element of double length therebetween. Typically, a web of tipping paper is supplied, adhesive is applied to one side of the paper web, the web is cut to provide a segment of desired size, the segment is applied to the aligned dual filter and tobacco rods, and rotation of the components causes the paper segment to wrap around the filter and tobacco rod components.

The selection of a particular filter element or mouth-end piece of the filtered cigarette tube can vary, and will be readily apparent to those skilled in the art of cigarette design and manufacture. The composition, size, format and configuration of the filter element can be a matter of design choice. Preferred filter elements are composed of plasticized cellulose acetate tow. Filter elements also can be composed of materials such as polypropylene tow, gathered polypropylene web, gathered cellulose acetate web or gathered paper. Representative filter elements can incorporate flavors, flavored threads, flavored pellets, breakable capsules, catalytic materials, interactive resin particles, activated carbon particles, and the like. Exemplary filter elements, including multi-segment filter elements, are set forth in U.S. patent application Ser. No. 11/377,630 to Crooks et al.; which is incorporated herein by reference.

The cigarette tubes can be provided with perforations in order to provide for air-dilution of finished cigarettes produced therefrom. Representative manners and methods for perforating manufactured cigarettes using laser systems are set forth in U.S. Pat. Nos. 4,281,670 to Heitmann et al.; U.S. Pat. No. 4,500,770 to Vock et al.; U.S. Pat. No. 4,565,202 to Seragnoli et al; U.S. Pat. No. 4,600,027 to Houck et al.; U.S. Pat. No. 4,825,883 to Hinz et al.; U.S. Pat. No. 4,889,140 to Lorenzen et al.; U.S. Pat. No. 5,060,668 to Weinhold and U.S. Pat. No. 6,675,811 to Dombeck; U.S. Pub. No. 2005/0103355 to Holmes; and EP 1072200 to Dombeck; which are incorporated herein by reference. Methods for rolling cigarettes in controlled manners (e.g., providing controlled rotation) in order that regions of those cigarettes can be appropriately treated (e.g., using laser systems) are set forth in U.S. Pat. No. 4,781,204 to Barbe et al.; U.S. Pat. No. 4,827,947 to Hinz; U.S. Pat. No. 5,690,125 to Niemann et al.; U.S. Pat. No. 6,526,985 to Bombeck and U.S. Pat. No. 6,532,966 to Dombeck; which are incorporated herein by reference.

Finished cigarettes that are air-diluted or ventilated can possess an amount or degree of air dilution or ventilation that can vary. Frequently, the amount of air dilution for an air-diluted finished cigarette is greater than about 10 percent, generally is greater than about 20 percent, often is greater than about 30 percent, and sometimes is greater than about 40 percent. Typically, the upper level for air dilution for such an air-diluted cigarette is less than about 80 percent, and often is less than about 70 percent. As used herein, the term “air dilution” is the ratio (expressed as a percentage) of the volume of air drawn through the air dilution means to the total volume of air and smoke drawn through the cigarette and exiting the mouth end portion of the cigarette.

Preferably, the finished cigarettes are conveyed directly to an apparatus for removing the filler material so that cigarettes can be manufactured and converted to empty, pre-formed cigarette tubes in an automated, in-line manufacturing process. Such a process would enable mass production of a large number of consistent and uniform pre-formed cigarette tubes.

Accordingly, the apparatus for removing the filler material is preferably attached in-line with the cigarette making machine. Finished cigarettes may be transferred from the tipping device by a rotating drum. Those cigarettes can be transferred to a conveyor belt to a suitable reservoir for transfer to a device for removing the filler material therefrom. Alternatively, those cigarettes can be transferred to another series of transfer drums equipped with components designed to reciprocate and hence encapsulate the filter section or region of each cigarette. Preferably, care is taken to ensure that the non-filter end of each cigarette is not deformed, blocked or undesirably squeezed together. Then, at an appropriate time and location, a burst or pulse of high velocity air into the filter end of the cigarette can cause the filler material to be blown from the cigarette.

In a preferred embodiment of the present invention, the filler material is ejected from the cigarette using an apparatus for ejecting filler that is similar to the apparatus described in U.S. Pat. No. 4,763,673 to Barnes, which is incorporated herein by reference, or other suitable apparatus. If desired, vacuum devices that are commonly employed during indexing to check the quality of air-diluted filtered cigarettes (e.g., the types of technologies provided by sources such as Carrier and Key Technologies) may be suitably modified so as to supply air to blow out filler material, rather than apply vacuum to the cigarette. Alternatively, the filler material may be sucked out of the cigarette using a vacuum device or the filler material may be removed from the cigarette by any other means that suitably removes the filler material from the cigarette to yield a pre-formed cigarette tube that is substantially devoid of filler material.

Each pre-formed tube so provided then continues movement until it is transported to an appropriate location. For example, the tubes can be transported to a conveyor belt (e.g., mass flow conveyor belt). The tubes can be examined visually and by weight in order to confirm that those tubes are of desired quality and then packaged.

The filler material that is ejected from the cigarettes may be collected and recycled to the cigarette making machine for use in making new cigarettes. An exemplary method of recovering filler material that is ejected from the finished cigarettes is described at column 5, lines 54-63 of U.S. Pat. No. 4,763,673 to Barnes. The collected filler may be transferred to the cigarette making machine using a conveyer system, rollers, automated mass flow, or the like. The recycled filler may be the sole source of filler for the cigarette making machine or it may be combined with fresh filler before being conveyed to the cigarette making machine.

The filler material removed from the cigarettes may be screened, or otherwise processed in order ensure that a continuous supply of filler of consistent quality is provided. An example of a process for screening the recycled filler materials is described in FIG. 4. For example, the filler material can be conveyed on a vibratory conveyor using a “two stage” screening process. That is, the filler material can be grossly screened to collect large size materials, such as large pieces of wrapping material or pieces of filter material; then, the filler material can be screened on a fine screen in order to sieve out or otherwise remove dust and fines. Suitable vibratory conveyor systems for tobacco filler are commercially available, and an example of a suitable device is available from Decouffle. In addition, suitably modified “on machine tobacco reclamation devices,” such as Decouffle Model DWR, can be employed. The filler material then can be stored in a suitable reservoir, or returned directly to the filler input region of the cigarette making machine. Techniques for movement of that filler material typically involve the use of pneumatic conveyor systems, and if desired, cyclone separators can be used in order to further ensure the consistency of the make up of the filler material. The filler material so provided then can be returned to the cigarette making machine. For example, the filler material may be returned to the cigarette making machine through the trim return conveyor of a Protos cigarette making machine that is operated in an essentially traditional manner). Additionally, the filler material may be aerated, humidified, cooled, or warmed in order to obtain the desired density, moisture content or temperature.

Optionally, the system may include an apparatus for monitoring the quality and characteristics of the filler material that is ejected from the finished cigarettes. The quality and consistency of the filler material may affect the quality and consistency of the pre-formed tubes. For example, if the density and moisture content of the filler material changes over time, the shape and quality of the empty tubes may also change over time. Accordingly, it is sometimes desirable to monitor and control the quality of the recycled filler. In this regard, an apparatus may be used to monitor the quality of the filler material. The characteristics of the filler material that may be monitored typically include, but are not limited to, density and particle size. Density and/or particle size may be monitored according to the screening techniques described above. Filler material that does not meet a pre-determined standard for some or all of these characteristics may be discarded, in whole or in part. Alternatively, the recycled filler material may be mixed with a sufficient amount of new filler to bring the overall quality of the filler material up to the pre-determined standard.

The resulting pre-formed filtered cigarette tubes can be collected and packaged for distribution to consumers or retailers. Preferably, the capture of the cigarette tubes is accomplished by automated mass flow and then packaged.

The pre-formed cigarette tubes may be used by consumers to make their cigarettes using hand operated cigarette making machines. Alternatively, the tubes may be used in commercial, mass-production cigarette making operations.

The pre-formed cigarette tubes are used for the manufacture of cigarettes. Various representative types of cigarette components are set forth in U.S. Pat. No. 5,220,930 to Gentry; U.S. Pat. Pub. Nos. 2004/0255965 to Perfetti et al.; 2004/0261807 to Dube et al.; 2005/0066982 to Clark et al. and 2005/0066986 to Nestor et al.; and U.S. patent application Ser. No. 11/375,700, filed Mar. 14, 2006, to Thomas et al.; which are incorporated herein by reference. See, also, Johnson, Development of Cigarette Components to Meet Industry Needs, 52nd T.S.R.C. (September, 1998).

The pre-formed cigarette tubes may also be used in retail establishments that provide for the custom manufacture of cigarettes according to the personal choices and preferences of retails customers. Such a retail establishment is operating as Marshall McGearty Tobacco Lounge at 1553 North Milwaukee Avenue, Chicago, Ill., USA.

Certain embodiments of the present invention may provide various advantages over known techniques for the manufacture of certain traditional types of pre-formed tubes. Certain traditional types of pre-formed filtered tubes are manufactured by inserting filter segments at predetermined locations within a continuous web of cigarette wrapping material, and forming a continuous series of pre-formed tubes that are sub-divided at desired locations to provide segments of the desired length; and those segments then are tipped with a type of tipping material in order to provide the look of traditional filtered cigarettes. Typically, those types of pre-formed tubes are limited in selection filter length (e.g., typical filter lengths are selected at about 15 mm to about 20 mm), rod circumference, draw or draft, “tar” removal efficiency, air dilution levels, and the like. Pre-formed filtered tubes of the present invention may be produced so that the components (e.g., selection, design and format of wrapping materials and filter materials), air dilution levels, rod dimensions, filter dimensions, and the like, can be selected and controlled. Furthermore, the pre-formed filtered tubes of the present invention may not require that the wrapping material of the smokable rod portion extend over the entire length of the cigarette, as is necessarily required for certain traditional types of pre-formed tubes that are manufactured using certain other types of techniques. In addition, the pre-formed tubes of the present invention can be produced so as to be virtually identical to the relevant components of cigarettes manufactured commercially using automated cigarette making machines.

The present invention provides a cigarette manufacturer with the ability to become highly versatile when manufacturing pre-formed filtered cigarette tubes. A wide variety of designs, formats and configurations can be incorporated into pre-formed filter cigarette tubes. As such, there is provided an ability to produce quality cigarettes at a later time by stuffing those cigarettes with tobacco filler, tobacco filler cartridges, or the like, which cigarettes are comparable in many respects to commercially manufactured cigarettes. Thus, a manufacturer of commercially manufactured finished cigarettes can provide pre-formed filtered tubes identical to the relevant components of those commercially manufactured cigarettes, and provide a blended tobacco cut filler identical to that of the commercially manufactured cigarettes; and hence, there can be constructed finished cigarettes from those tubes and tobacco cut filler that can match or approach the performance (e.g., yields, draw, flavor, and the like) of the commercially manufactured cigarettes.

It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. 

1. A method of manufacturing a pre-formed cigarette tube, said method comprising the steps of: a. manufacturing a cigarette using a cigarette making machine, the cigarette comprising filler material; b. transferring the cigarette to an apparatus for removing the filler material from the cigarette; and, c. removing the filler material from the cigarette.
 2. The method of claim 1, further comprising the steps of: d. collecting the filler material that is removed from the cigarette; and e. transporting the filler material collected in step (d) to the cigarette making machine.
 3. The method of claim 2, further comprising the step of: f. measuring one or more characteristics of the filler material after the filler material is collected and before it is transported to the cigarette making machine.
 4. The method of claim 3, further comprising the steps of: g. comparing the one or more characteristics of the filler to a pre-determined standard; and h. discarding any filler that does not meet the pre-determined standard.
 5. The method of claim 3, wherein the one or more characteristics of the filler material are selected from the group consisting of: density, moisture content, temperature and particle size.
 6. The method of claim 1, wherein each step of the method is in-line and machine automated.
 7. The method of claim 2, further comprising the step of: f. screening the recovered filler material that is transported to the cigarette making machine.
 8. The method of claim 1, wherein the filler material comprises a non-tobacco material.
 9. The method of claim 1, wherein the cigarette comprises a filter.
 10. The method of claim 1, wherein the filler material is removed from the cigarette with a burst of air.
 11. A machine for manufacturing pre-formed cigarette tubes, the machine comprising: a. a cigarette making machine, wherein the cigarette making machine manufactures cigarettes that include filler material; b. an apparatus for removing the filler material from the cigarettes; and, c. an apparatus for transporting the cigarettes from the cigarette making machine to the apparatus for removing the filler material.
 12. The machine of claim 11, wherein the cigarette making machine manufactures cigarettes that include filler material and a filter.
 13. The machine of claim 11, wherein the filler material comprises tobacco.
 14. The machine of claim 11, wherein the filler material comprises a non-tobacco material.
 15. The machine of claim 11, wherein the apparatus for removing the filler material removes filler material from the cigarette with a burst of air.
 16. The machine of claim 11, further comprising: d. an apparatus for recovering the filler material that is removed from the cigarettes, and e. an apparatus for transporting the recovered filler material to the cigarette making machine.
 17. The machine of claim 16, further comprising: f. an apparatus for screening the recovered filler material that is transported to the cigarette making machine.
 18. The machine of claim 16, further comprising: f. an apparatus for measuring one or more of the following characteristics of the filler material: density, moisture content, temperature and particle size.
 19. The machine of claim 11 wherein each of the components is in-line and machine automated so that the machine is capable of the continuous and automated manufacture of pre-formed cigarette tubes.
 20. The machine of claim 16 wherein each of the components is in-line and machine automated so that the machine is capable of the continuous and automated manufacture of pre-formed cigarette tubes. 